retrofit a1 refrigerants
TRANSCRIPT
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 1
Preparation for Wholesaler Presentation Select 8
Retrofit A1 Refrigerants
2019 Wholesale Conference
Andreas Peselmann
Application Engineering
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 2
Agenda
• Refrigerants Overview
• Conclusions For Retrofitting
• Retrofitting Existing R404A Systems, Scroll + Semihermetic
• Retrofitting ZB56-11 TW*, ZS56-11 TW*, ZF24-48 TW*
• Retrofitting Existing R134a Systems, Scroll + Semihermetic
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 3
Refrigerant Options
R-410A
Like
Capacity
R404A &
R407/22
Like
R134a
Like
GWP Level
400-675
< 1500
~600HFO 1234yf
HFO 1234ze
R410A
R22
R407A
R407C
R407F, R452A
0 500 1000 1500 2000
Cooling Capacity
System Pressure
R32/HFC/HFO
Blends
R32/HFO
Blends
HFC/HFO
BlendsR134a
CO2
R404A
R507A
R290
NH3
A1 – Non Flammable
A2L – Lower Flammable
A3 – Higher Flammable
B2L – Toxic, Mildly Flam.Qualitative Chart –
Not To Scale
(3922)
R32/HFO
Blends R448A/R449A
R450A
R513A
<150 R455A (HDR110)
R454C (DR3)
R32 R452B (DR55)R454B
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 4
Refrigerant safety classification, according to ISO 817 .
Refrigerant Classification
Flammability
A3 B3 Higher Flammable
A2 B2 Flammable
A2L B2L Lower Flammable
A1 B1 Non Flammable
ToxicityLow
Toxicity
High
Toxicity
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 5
Refrigerant Classification
• refrigerant safety classification per ISO 817
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 6
Refrigerant Classification
• overview refrigerant safety
classification EN378-1, Annex E
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 7
Legislation and Safety
• system design safety devices and components depend on the refrigerant safety
class, like A1, A2L or A3
• A1 system design, safety and legislation is well known
• A2L and A3 system design have other requirements
- legislation (general, local) must be considered
- specific product norms, like for example EN60335-2-89 might work
- otherwise EN378 comes into place
- impact on system design, components selection, refrigerant filling, safety concept
- ped classification +1 for flammable refrigerants
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 8
Refrigerant And System Classification
Conclusions:
• A2L and A3 refrigerants for new systems only. The system and safety architecture
must be adapted to be appropriate for A2L and A3
• systems designed for A1 refrigerant, could only be operated with A1 refrigerants
• retrofit of an existing A1 system with A2L or A3 refrigerant is NOT possible
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 9
Retrofit Existing Systems With R404A
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 10
Retrofit Existing R404A Systems
Official Emerson released R404A
replacements:
R448A, R449A, R407A, R407F
-> see Select software for compressor
– refrigerant combination
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 11
Retrofit Existing R404A Systems, General Guidelines
Technical information for the refrigerant changeover from R404A
to R407A, R407F, R448A or R449A
• for Copeland compressors scroll + semi hermetic
• general advices
• changeover procedure
• pressure and temperature tables
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 12
Retrofit Existing R404A Systems, General Guidelines
Technical Information considerations:
• ester oil
• capacity and efficiency values
• discharge temperatures
• MT and LT operation envelopes
• material compatibility (gaskets)
• density and mass flow (piping)
• suction and discharge pressures (adjusting valves)
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 13
Retrofit Existing R404A Systems, General Guidelines
Technical information considerations:
• R407A, R407F, R448A and R449A are
blend refrigerants
-> temperature glide to be considered
Example: -10°C evaporating => 2,6 bar,g R448A
for the correct superheat measurement and calculation,
the dew point must be used.
-> eventually new expansion valve
-> expansion valve settings must be adapted
Warning: using the old R404A expansion valve without adapting, could damage the compressor!
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 14
Retrofit Existing R404A Systems, Scroll
MT + LT applications scroll.
compressor envelope
-> check for possible restrictions in terms of
suction gas return temperature or
superheat
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 15
Retrofit Existing R404A Systems, Scroll
MT + LT applications scroll
Capacity value comparison:
R404A vs replacement refr.
-> Select enables a direct comparison
of both refrigerants
-> replacement refrigerant might have
less cooling capacity
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 16
Retrofit Existing R404A Systems, Scroll
MT applications scroll.
Envelope comparison: R404A vs replacement
refrigerant
-> Select enables a direct comparison of the possible
operation envelope
-> for MT applications usually the envelope of the
R404A replacement refrigerant fits quite good!
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 17
Retrofit Existing R404A Systems, Scroll
LT applications scroll with liquid injection
Envelope comparison: R404A vs replacement
refrigerant
-> due to liquid injection technology, mostly the
envelope fits quite good!
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 18
Retrofit Existing R404A Systems, Scroll
LT applications scroll with vapour injection
Envelope comparison: R404A vs replacement
refrigerant
-> care must be taken for the pure EVI envelope
-> operating area with wet injection required
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 19
Retrofit Existing R404A Systems, Semih.
MT applications semihermetic.
Envelope comparison: R404A vs replacement
refrigerant
-> Select enables a direct comparison of the possible
operation envelope
-> for MT applications usually the envelope of the
R404A replacement refrigerant fits quite good!
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 20
Retrofit Existing R404A Systems, Semiherm.
LT applications semihermetic
Envelope comparison: R404A vs replacement
refrigerant
-> compare envelope with/without liquid injection
Demand Cooling DC
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 21
New Service BOM 951
ZB56-11KE/ME, ZS56-11KE/ME, ZF24-48K4E/KVE
Retrofit Options
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 22
New Service BOM951 ZB56-11KE/ME, ZS56KE/ME, ZF24-48K4E/KVE TW*
Old „Specter“ compressor families still remain in
production, but now sold with service BOM 951
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 23
ZB56-11KE/ME, ZS56KE/ME, ZF24-48K4E/KVE TW*
• Compressor series for service
purposes only
• Technical data still available under
„previous generation“
• Old data shown for R404A, R22,
R134a...
• No new refrigerant qualification, such
as R448A/R449A, R407A, R407F.
-> no technical data in Select
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 24
ZB56-11KE/ME, ZS56KE/ME, ZF24-48K4E/KVE TW*
• Estimation of capacity values,
application envelopes possible with
comparison to newer model range,
see Select software:
- select old compressor and new
compressor family based on R404A
- select similar/comparable
displacement
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 25
ZB56-11KE/ME, ZS56KE/ME, ZF24-48K4E/KVE TW*
• Estimation of capacity values,
application envelopes possible with
comparison to newer model range,
see Select software:
- use new compressor family/model
as baseline for new refrigerant
calculation
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 26
ZB56-11KE/ME, ZS56KE/ME, ZF24-48K4E/KVE TW*
• estimation of capacity values,
application envelopes possible with
comparison to newer model range,
see Select software:
- use new compressor family/model
envelope for estimation of possible
operation range
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 27
ZF24-48 K4E TWD with liquid injection
ZF24-48 K4E TWD Specter family compressors with liquid injection
• Technical Information for the conversion of existing R404A systems
with capillary tube towards DTC valve liquid injection available
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 28
Retrofit Existing R404A Systems, Semihermetic
Old „previous generation“ compressor families, new technical data
• Compressor model families, which have been identified as phase-out
or obsoleted products have not been qualified for new refrigerants, such
as R448A, R449A ect.
Examples: DWM Models D2S*, D3S*, D4S*, D6S* D8S*, D4D*, D6D*, D6T*
• Consequently, there are no technical data in Select available.
• Theoretical calculated data for specified operation points could be provided on request
• Valuation of the possible operation envelope: comparison with released Stream models
Example:
MT Old: D4DH 250X (70,8 m³/h) 4MH 25X (71,4 m³/h)
LT Old: D4DL 150X (70,8 m³/h) 4ML 15X (71,4 m³/h)
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 29
Retrofit Existing Systems With R134a
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 30
Retrofit Existing R134a Systems
Official Emerson released R134a replacements:
R450A, R513A
• R450A (N13), A1 safety class, GWP 605
composition R134a (42%), R1234ze (58%)
• R513A (XP10), A1 safety class, GWP 631
composition R134a (44%), R1234yf (56%)
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 31
Retrofit Existing R134a Systems
R450A, R513A qualification
• refrigerant migration of liquid R450A/R513A
into the compressor crankcase could cause
low oil viscosity and compressor damage.
When using R450A and R513A with the
standard compressor versions, it is critical to
meet some application requirements.
For new systems/applications with R513A/R450A:
Emerson offers a new compressor family
ZR24-92 KRE + ZRD36-92 KRE
launch planned for Q1 2019
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 32
Retrofit Existing R134a Systems
R450A, R513A retrofit scrolls in the field
Dedicated application recommendations:
• maintain adequate superheat settings
with a minimum superheat of 8-10K
• no liquid refrigerant migration into the compressor at any time, especially during standstill, during
or after defrost, or after reverse mode for example in heat pumps
• pumpdown is recommended
• the use of a crankcase heater is mandatory;
• for R450A and R513A refrigerants Emerson recommends to use suction accumulators, unless it
has been qualified that an accumulator is not needed (procedure described in the Application
Guidelines).
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 33
Retrofit Existing R134a Systems, General Guidelines
Technical information for the refrigerant changeover from R134a
to R450A + R513A
• for Copeland compressors scroll + semi hermetic
• general advices
• changeover procedure
• pressure and temperature tables
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 34
Retrofit Existing R134a Systems, General Guidelines
Technical Information considerations:
• ester oil
• capacity and efficiency values
• discharge temperatures
• MT and LT operation envelopes
• material compatibility (gaskets)
• density and mass flow (piping)
• suction and discharge pressures (adjusting valves)
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 35
Retrofit Existing R134a Systems, Scroll
compressor envelopes R134a, R450A, R513A
-> compressor ebvelopes are quite comparable
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 36
Retrofit Existing R134a Systems, Scroll
Capacity value comparison:
-> Select enables a direct
comparison between all three
refrigerants
WHS Workshop 2019, Retrofit A1 Refrigerants, Slide 37
Retrofit Existing R134a Systems, Semih.
compressor envelopes R134a, R450A, R513A
-> compressor envelopes are quite comparable